Automatic drill fluid measurement apparatus

ABSTRACT

The present invention is directed to an automatic drill fluid measurement apparatus. More specifically, the present invention is directed to an apparatus which may automatically measure a weight or volume of a quantity of drill fluid and provide real-time feedback information regarding the drill fluid to a well operator. The automatic drill fluid measurement apparatus may further comprise a variety of sensors and other devices that are used in conjunction with a microprocessor to obtain useful information regarding drill fluid, such as mass flow meters, volume sensors and timers. Together, the apparatus, sensors and microprocessor may work together to control the opening and closing of valves of the measurement apparatus.

This application claims the benefit of U.S. Provisional Application No. 61/825,626, filed May 21, 2013.

FIELD OF THE INVENTION

The present invention is directed to an automatic drill fluid measurement apparatus. More specifically, the present invention is directed to an apparatus which may automatically measure a weight or volume of a quantity of drill fluid and provide real-time feedback information regarding the drill fluid to a well operator. The automatic drill fluid measurement apparatus may further comprise a variety of sensors and other devices that are used in conjunction with a microprocessor to obtain useful information regarding drill fluid, such as mass flow meters, volume sensors and timers. Together, the apparatus, sensors and microprocessor may work together to control the opening and closing of valves of the measurement apparatus.

BACKGROUND

This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the presently described embodiments. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present embodiments. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.

In the field of oil exploration and downhole drilling, a variety of downhole fluids may be used in the drilling process. For instance, when drilling in a hydrocarbon producing formation, drill fluids may be used to lubricate and cool a drill bit while simultaneously removing and transporting cuttings such as bits and pieces of rock formation cut or dislodged by the drill bit. Other uses for drill fluid in a drilling operation include controlling the fluid within a formation to prevent blowouts, stabilizing a well, suspending solids within a well, as well as fluid displacement to flush out a particular fluid downhole. Further, drill fluids may be used to otherwise clean a well and test the downhole conditions within the well.

Most often, the drill fluid is used to provide cooling and lubrication for the drill bit and to carry away the cuttings from the earth or rock formation. The drill fluids are typically pumped downhole through the tubing and orifices located on the drill bit so as to directly lubricate the cutters located on the drill bit. The cuttings are then carried to the surface of the well and the drill rig via the return flow through the well annulus. Naturally, the returned drill fluid will contain small pieces of shale or rock from the formation being cut. Therefore, the cuttings are separated from the drill fluid and the fluid is cleaned and recycled for future drill operations. The cleaning process generally occurs simultaneously with drilling of the well. Thus, so long as the well is being drilled, well fluid is continuously circulated downhole and back up to the surface with return fluid and cuttings to be cleaned from the drill fluid.

As a result, it is important that a well operator is able to stay apprised of various information regarding the drill fluids currently being circulated in a downhole well. In particular, a well operator needs to know how much fluid is being pumped downhole as well as the condition and composition of the fluid. Further, it is desired that the information is provided to the well operator in real-time so that on-the-fly adjustments may be made to various aspects of the drill rig.

SUMMARY OF THE INVENTION

Certain aspects of some embodiments disclosed herein are set forth below. It should be understood that these aspects are presented merely to provide the reader with a brief summary of certain forms the invention might take and that these aspects are not intended to limit the scope of the invention. Indeed, the invention may encompass a variety of aspects that may not be set forth below.

The present invention provides a unique and novel apparatus and method for measuring drill fluid to be used during drilling operations, and for providing feedback information to a well operator in real-time regarding various conditions of the fluid. In particular, the present invention may directly or indirectly measure the weight, volume and/or viscosity of a given quantity of drill fluid and provide such information instantaneously to a well operator so that further corrective action may be taken.

Various refinements of the features noted above may exist in relation to various aspects of the present embodiments. Further features may also be incorporated in these various aspects as well. These refinements and additional features may exist individually or in any combination. For instance, various features discussed below in relation to one or more of the illustrated embodiments may be incorporated into any of the above-described aspects of the present disclosure alone or in any combination. Again, the brief summary presented above is intended only to familiarize the reader with certain aspects and contexts of the embodiments without limitation to the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages of certain embodiments will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

FIG. 1 is perspective view of an embodiment of an automatic drill fluid measurement apparatus made in accordance with principles of the present invention described herein;

FIG. 2 is a frontal view of the measurement apparatus shown in FIG. 1;

FIG. 3 is a side view of the measurement apparatus shown in FIG. 1;

FIGS. 4A-4C illustrate bottom, frontal and side views of a preferred embodiment of the beaker shown in FIGS. 1-3;

FIG. 5 is a perspective view of an alternative embodiment of an automatic drill fluid measurement apparatus made in accordance with principles of the present invention described herein;

FIG. 6 is a frontal view of the measurement apparatus shown in FIG. 5; and

FIG. 7 is a side view of the measurement apparatus shown in FIG. 5.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

One or more specific embodiments of the present disclosure will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking of design, fabrication and manufacture for those of ordinary skill having the benefit of this disclosure.

When introducing elements of various embodiments, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Moreover, any use of “top,” “bottom,” “above,” “below,” other directional terms, and variations of these terms is made for convenience, but does not require any particular orientation of the components.

Turning to FIG. 1, a perspective view of an embodiment of an automatic drill fluid measurement apparatus 10 is shown. Measurement apparatus 10 may include a frame 100, which may be a cabinet or a set of metallic frameworks. In the embodiment shown, measurement apparatus 10 has a beaker assembly 120 comprising a fluid vessel or beaker 124 connected to a top plate 110, which is mounted to frame 100. Beaker 124 is securely attached to top plate 110 via a variety of methods known in the art, such as bolts or fasteners. In particular, beaker 124 is attached to a central recess of top plate 110 for mounting beaker 124 therein. Beaker 124 may be a container shaped and sized to hold a particular quantity of drill fluid with a supply opening 123 located at the top of beaker 124 and a nozzle or discharge opening 125 located at the bottom of beaker 124.

Supply opening 123 may be appropriately shaped and sized to be able to receive a quantity of drill fluid 20 from a drill fluid supply line 122, which is shown located above beaker 124. In embodiments of the invention, supply line 122 may be made of a corrosion resistant material appropriate for handling the inbound flow of drill fluid 20, and may be mounted to frame 100 or may be mounted to another part of the drill rig apart from measurement apparatus 10. The diameter of supply line 122 may be sized to have a diameter smaller than the width or length of supply opening 123. This is so that drill fluid 20 flowing from supply line 122 does not spill outside of beaker 124 unless beaker 124 is presently overflowing. By way of example only, in an embodiment of the invention, supply line 122 may have a diameter of approximately one inch.

An electronic supply valve 132 may be connected to supply line 122 to control the flow of drill fluid 20 into beaker 124, with control of supply valve 132 being handled by a microcontroller or processor. Supply valve 132 may be selected from a variety of valves known in the art. Other valves are also contemplated within the scope of the present invention, and may accordingly be substituted for supply valve 132.

Similar to supply line 122, a rinse fluid supply line 130 may also be similarly situated above beaker 124 for direct discharge of a rinse fluid 22 into beaker 124. Rinse fluid supply line 130 may be made of a corrosion resistant material appropriate for handling the flow of rinse fluid 22, and may also be mounted to frame 100 or may be mounted to another part of the drill rig apart from measurement apparatus 10. As with supply line 122, the diameter of rinse line 130 may be sized to have a diameter smaller than the width or length of supply opening 123 located on beaker 124. This is so that rinse fluid 22 flowing from rinse line 130 does not spill outside of beaker 124 unless beaker 124 is presently overflowing. An electronic rinse valve 140 may be connected to rinse line 130 to control flow of rinse fluid 22 into beaker 124, with control of supply valve 132 being handled by a microcontroller or processor. As with supply valve 132, rinse valve 140 may be selected from a variety of valves known in the art.

The substantially circular discharge opening 125 may be located at the bottom of beaker 124 to facilitate discharge of drill fluid 20 or rinse fluid 22 from beaker 124 upon actuation of a discharge valve 134. A cylindrically shaped discharge line 128 is fluidly connected to discharge opening 125 such that fluids 20 or 22 may readily flow from beaker 124 through discharge line 128 to a storage location or other line where fluids 20 and 22 may be used or processed. Because the discharge of fluids from beaker 124 is facilitated by gravity, discharge line 128 may be of sufficient length to allow for all fluids within beaker 124 to readily exit beaker 124. Correspondingly, beaker 124 may be mounted at a sufficient height to allow for gravity assisted discharge of fluids within beaker 124 when discharge valve 134 is actuated to an open position.

FIG. 1 further illustrates the use of one or more load cells 126 on measurement apparatus 10. Load cells 126 are essentially transducers which are capable of converting a given force into an electrical signal and are known in the art. Load cells 126 may be selected from a variety of load cell configurations, including hydraulic load cells, pneumatic load cells or strain gauge load cells. Other types of load cells 126 may be contemplated within the scope of the present invention. As shown in FIG. 1, load cells 126 may be located adjacent to beaker 124, and more specifically, connected to top plate 110. That is, beaker 124 is directly attached to top plate 110, and top plate 110 rests upon load cells 126. Load cells 126 are also connected to frame 100. Thus, it can be more readily understood that the weight of beaker 124 (and its contents), top plate 110, discharge line 128, and discharge valve 134 bear down on the one or more load cells 126. Further, as understood by this relationship, top plate 110 and beaker 124 are not directly connected to frame 100, but rather are interconnected to frame 100 via the one or more load cells 126. As shown in FIG. 1, two load cells 126 are utilized to measure the weight of beaker 124 (and its contents), however, in other embodiments of the invention, a greater or fewer number of load cells 126 may be utilized.

Through this particular configuration, load cells 126 may be able to measure the weight of beaker 124 (and its contents) and forward this information electronically to a microcontroller or processor for further processing into useful information for a well operator. It is understood that the weight of the top plate 110 and beaker 124 are accounted for and zeroed-out by the microcontroller or processor in determining the true weight of any fluids residing within beaker 124.

In addition to beaker 124, a secondary beaker 136 may be provided in an alternative embodiment of the invention. Secondary beaker 136 may be located below beaker 124 and discharge line 128 so as to collect the discharge of fluid from beaker 124 and discharge line 128. As shown in FIG. 1, secondary beaker 136 may be similarly mounted as beaker 124, except that secondary beaker 136 is mounted on bottom plate 112 rather than top plate 110. Secondary beaker 136 may be similarly shaped and sized with beaker 124 in order to retainer a quantity of fluid deposited within secondary beaker 136 via discharge line 128. Further, secondary beaker has a width and length that is greater than the diameter of discharge line 128 so that fluids entering secondary beaker 136 do not spill out of the sides of the beaker.

Unlike top plate 110, bottom plate 112 may be directly connected to frame 100 due to the lack of any load cells 126 connected to bottom plate 112. A secondary discharge line 138 may be fluidly connected to the bottom of secondary beaker 136 so as to discharge fluid away from measurement apparatus 10. Secondary discharge line 138 may also be cylindrically shaped and have a similar diameter to discharge line 128.

Turning to FIG. 2, therein is shown a side view of the embodiment of measurement apparatus 10 from FIG. 1. Here, various features of the invention are more readily viewable, such as the relative location of load cells 126 in relation to top plate 110. As described previously, measurement apparatus 10 includes frame 100 upon which various other elements of the invention are connected or interconnected thereon. Top plate 110 is provided with beaker 124 connected and suspended from top plate 110. Discharge line 128 and connected discharge valve 134 are attached to the bottom of beaker 124, with the top of discharge line 128 fluidly connected to discharge opening 125 located at the bottom of beaker 124.

One or more load cells 126 may be mounted to frame 100 to provide electrical signaling of a force applied thereon. Top plate 110 is connected to the one or more load cells 126, which are able to measure a force exerted by the weight of beaker 124 in combination with any fluids therein. Secondary beaker 136 may be attached to bottom plate 112 and secondary discharge line 138 is seen connected to the bottom of secondary beaker 136. In particular, it can be seen that secondary discharge line 138 has an elbow 139 to direct flow of fluids 20, 22 out through a side of measurement apparatus 10 rather than continuing downward.

FIG. 3 illustrates a side view of measurement apparatus 10, as taken from the left side of the apparatus. Here it can be seen in combination with FIG. 2 that drill fluid supply line 122 and rinse fluid supply line 130 are located above beaker 124 such that fluid flow from lines 122, 130 will discharge directly into supply opening 123 of beaker 124. Similarly, FIGS. 2 and 3 illustrate that discharge line 128 will discharge a fluid directly into secondary beaker 136.

FIGS. 4A-4C illustrate bottom, frontal and side views of a preferred embodiment of beaker 124. As can be seen in FIGS. 4A-4C, supply opening 123 and discharge opening 125 may be located at the top and bottom of beaker 124 to facilitate receiving and discharging drill and rinse fluids 20, 22. In particular, it can be seen that supply opening 123 spans the length and width of beaker 124 to allow for easy filling of beaker 124 during fluid measurement operations. Discharge opening 125 is smaller than supply opening 123 and provides for centralized discharge of fluids through discharge line 128.

FIG. 5 depicts an alternative embodiment of the present invention, with measurement apparatus 10 having an additional enclosure 102 for enclosing and protecting the various components of measurement apparatus 10. Enclosure 102 may be fabricated from a non-corrosive metal and may be shaped to enclose all components of measurement apparatus 10 and, further, may include vents for the passage of gases between the inside and outside of enclosure 102. Further, enclosure 102 may include various openings 104 to allow for passage of various fluid lines between the inside and outside of measurement apparatus 10. Additionally, a level probe 142 may be seen in this figure, which may be used to measure the level of fluid residing within beaker 124. Other methods for measuring the fluid inside beaker 124 may also be available, the details of which will be further described below.

As can be seen in FIG. 5, various other aspects of measurement apparatus 10 remain the same despite the inclusion of enclosure 102. For instance, the use of drill fluid supply line 122, beaker 124, discharge line 128, rinse fluid supply line 130, and discharge valve 134 remain from the embodiments shown in FIGS. 1-4. Other components not shown in the embodiment of FIG. 5 may also be included or excluded depending upon the functionality desired by the well operator.

FIGS. 6 and 7 illustrate respective frontal and side views of the embodiment of measurement apparatus 10 shown in FIG. 5, and further serve to illustrate the various components of measurement apparatus 10 when an enclosure 102 is utilized. As shown in FIG. 6, the particular placement and orientation of supply line 122 and rinse line 130 within enclosure 102 may be more clearly seen, along with the attendant valves 132, 140. Further, beaker 124 is shown as attached to top plate 110, which then rests upon load cells 126. Discharge line 128 is connected to the bottom of beaker 124 and extends downward therefrom, with discharge valve 134 attached to discharge line 128 to control flow out from beaker 124. It should be noted that in the embodiment shown in FIGS. 5-7, measurement apparatus 10 does not have a bottom plate 112, secondary beaker 136 or secondary discharge line 138. Rather, fluid is discharged from beaker 124 directly out of measurement apparatus 10 to a fluid line located elsewhere outside enclosure 102.

FIG. 7 provides a side view of the embodiment of measurement apparatus 10 shown in FIG. 5, and serves to illustrate the centralized placement of level probe 142 as well as discharge line 128 within enclosure 102.

Having described the various components associated with embodiments of measurement apparatus 10, a general description of the process steps for measuring drill fluid by measurement apparatus 10 will now be discussed. To begin, supply valve 132 is opened to allow a given quantity of drill fluid to flow into beaker 124 via supply line 122. Supply valve 132 is then closed so that the given quantity of drill fluid may be weighed by load cells 126 and the weight information electronically transmitted to a microprocessor or controller. The process of transmitting weight information may also occur while supply valve 132 is still open, thus transmitting multiple weight information as beaker 124 is being filled.

After filling beaker 124 with a given quantity of drill fluid, discharge valve 134 is opened to allow for the fluid residing within beaker 124 to discharge out through discharge line 128. At this time, rinse valve 140 is also opened to allow for rinse fluid 22 to wash down through beaker 124 as well as the now open discharge line 128. After a given period of time, rinse valve 140 is closed and discharge valve 134 is thereafter closed as well. Data is collected throughout this process and based upon the data collected, the weight of the fluid interned in beaker 124 may thereafter be calculated by the microcontroller or processor.

In various embodiments of measurement apparatus 10, an assortment of sensors may be utilized in conjunction with a microprocessor or controller to control the opening and closing of valves 132, 134 and 140. By way of example only, a mass flow meter may be attached to discharge opening 125 or some other point on discharge line 128 to measure the flow rate at the drain point. This would provide an accurate flow rate for calculation of viscosity of draining drill fluid 20. The mass flow meter may be attached external to the fluid flow path, thereby increasing reliability. In other embodiments of measurement apparatus 10, the mass flow meter may be connected to drill fluid supply line 122 rather than discharge line 128. Mass flow meter is additionally connected to a microcontroller or processor such that fluid flow rate may be accurately calculated by the microcontroller or processor.

In another embodiment, a volume sensor may be used, such as a LVDT sensor, and located within beaker 124. Such a sensor is electronic, and stem-style in design, with a stainless steel ball which may move up and down the sensor rod. Depending on the positioning of the steel ball along the sensor rod, the sensor may be able to relay fluid volume information associated with beaker 124 to a microcontroller or processor.

In another embodiment of measurement apparatus 10, a timer may be electrically connected to a microprocessor or controller. The timer may be utilized for timing various fluid flows within measurement apparatus 10, such as the time for beaker 124 to be completely filled with either drill fluid 20 or rinse fluid 22. Additionally, the timer may be used to measure the amount of time it takes to drain beaker 124. Alternatively, the timer may be used to calculate the viscosity of the drill fluid within beaker 124. By way of example, by recording the amount of time it takes for the beaker to evacuate fluid out through the bottom of beaker 124, and combining this information with the given size and surface area of beaker 124, fluid viscosity may be calculated by the microprocessor and this information provided to the well operator.

In yet another embodiment of the measurement apparatus 10, a bypass orifice may be attached to the top of beaker 124 to allow for incoming fluid to bypass beaker 124 when beaker 124 has been filled to a predetermined volumetric limit. This prevents beaker 124 from overflowing with drill fluid 20 or rinse fluid 22.

While the aspects of the present disclosure may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. But it should be understood that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the following appended claims. 

What is claimed is:
 1. An automatic drilling fluid measurement apparatus comprising: a frame; a beaker connected to the frame; a load cell connected to the frame and operable to measure the weight of the beaker; an electronic supply valve connectable to a drilling fluid supply line; the supply valve operable to control flow from the drilling fluid supply line into the beaker; an electronic rinse valve connectable to a rinse fluid supply line; a discharge line located at a bottom of the beaker; an electronic discharge valve located between the bottom of the beaker and the discharge line; an electronic controller electrically connected to the load cell, the electronic supply valve, the rinse valve, and the discharge valve; and, a timer electrically connected to the electronic controller.
 2. The automatic drilling fluid measurement apparatus of claim 1, further comprising: a level sensor located inside the beaker and electrically connected to the electronic controller.
 3. The automatic drilling fluid measurement apparatus of claim 1, further comprising: a nozzle at the base of the beaker.
 4. The automatic drilling fluid measurement apparatus of claim 1, further comprising: a bypass orifice to permit drilling fluid to bypass the beaker when the beaker has been filled to a predetermined volumetric limit.
 5. The automatic drilling fluid measurement apparatus of claim 1, further comprising: a mass flow meter connected to the supply line and electrically connected to the electronic controller and operable to measure the mass flow through the supply line when the supply valve is open.
 6. The automatic drilling fluid measurement apparatus of claim 1, further comprising: a mass flow meter connected to the discharge line and electrically connected to the electronic controller and operable to measure the mass flow through the discharge line when the discharge valve is open.
 7. The automatic drilling fluid measurement apparatus of claim 1, further comprising: the electronic controller programmable to perform the following operations: open the supply valve; close the supply valve; receive and store weight data from the load cells at measured increments in time; open the discharge valve; open the rinse valve; close the rinse valve; close the discharge valve; and, determine the weight of the fluid that was interned in the beaker.
 8. The automatic drilling fluid measurement apparatus of claim 1, further comprising: the controller electrically connected to a communication device operable to communicate the determined fluid weight to a drilling rig control system.
 9. The automatic drilling fluid measurement apparatus of claim 1, further comprising: measuring the time increment between opening the discharge valve and the weight of the beaker indicating that the beaker is empty.
 10. The automatic drilling fluid measurement apparatus of claim 1, further comprising: calculating an approximate fluid viscosity based on the time required to evacuate the beaker through the nozzle at the base of the beaker.
 11. A method of automatically measuring drilling fluid comprising: electronically weighing a beaker; opening a supply valve to permit drilling fluid to enter the beaker; closing the supply valve when the beaker contains a predetermined volume of fluid; electronically weighing the drilling fluid in the beaker; opening a discharge valve to permit the drilling fluid to evacuate the beaker; opening a rinse valve; closing the rinse valve; and, closing the discharge valve. 